Heating unit for hydrogenous and carbonaceous values recovery



June 27, 1933. 1,915,567

HEATING UNIT FOR HYDRoGENoUs AND cARBoNAcEoUs VALUES RECOVERY R. CARTER Filed March 25, 1926 2 Sheets-Sheet l l Illlllllll).

@mm @zo u kwal. .NN

Muang :ou N

H g k June 27, 1933. R, CARTER 1,915,567

HEATING UNIT FOR HYDROGENOUS AND CARBONACEOUS VALUES RECOVERY Filed March 23, 1926 2 Sheets-Sheet 2 f Z2 p C) 07` y M EE ELicTRlc/L 33u www@ Il@ ad: HEATER, p] @V76 E /7/ 7J UCI: )En C@ mi 77 di 33u. @D 72 pn 7 uq h1 2f 2f f" gvvvanfoz: if @55771 f77/7771i.

ELEcvRlcAL HEATER UNIT 7i www Patented `lune 27, 1.933

cii`

RUSSELL CARTER, OF WASHINGTON, DISTRICT OF COLUMBIA.

HEATING UNIT FOR HYDROGENO'US AND CAREON'ACEOUS VALUES RECOVER-Y i Application filed March 23, 1926. Serial No. 96,780.

V typiication ofthe invention is the effective utilization of electrical resistances for alfording the source of heat. ,y

YWith these'and other objects in view as will in part hereinafter become apparent and in part be stated, the invention comprises certain novel constructions, combinations and arrangements of parts as will be subsequently' specified and claimed. .y

Figure 1 is a diagrammatic illustration of a plant comprehending an embodiment of the structural features of the invention especially well adapted for carrying out the art, parts being seen in section for disclosing interior structure. y

Figure 2 is an enlarged, detail, fragmentary elevation of a part of the heatingV plant.

Figure 3 is a further enlarged, fragmentary sectional view through the end portion of one of the heating units, .the resistor and bus line being seen in elevation.

Figure 'il is an enlarged, detailed, fragmentary vertical section through one of the vdischarge nozzles of the difference-impressure reducingsystem. Y

Figure 5 is a view in side elevation of a fragment of the vapor line showing an electrical superheater interposed therein.-

Figure 6 is a plan view of the parts seen in Figure 5.

Figure 7 is an end view of the super-heater of Figures 5 and 6 detached.

Referring to the drawings by numerals, 1 indicates a source of supply, such as an elevated tanlr arranged in sufficient proximity to the heater 2 to be initially heated thereby.

l23, each cont The detail construction of the heater 2 is illustrated in Figures 2 and 3. The heater consists preferably of a series ofA units 3,3, each receiving a supply from a pipe or header l, and each discharging into a delivery pipe or exhaust header 5. The header 4 communi cates with a supply pipe 6 extending to and communicating with the tankl 1. A valve 7 controls the delivery.` of fluid fuel from pipe 6 to header l, and a valve 8 controls the delivery from the tanlr. into the pipe 6. The exhaust or discharge header 5 extends' into a percolating or cracking chamber 9, and is provided with a discharge spout 10 for delivering the heated oil or votherfiuid down on top of the contents of chamber 9. l

A formaninous false bottomll is arranged in the chamber 9 and supported in any appropriate way, such as y framing 12 resting on the removable bottom'13 of the chamber. The .plate 11 sustains the solids and provides an open space at the lower end porton of chamber 9 for the accumulation of liquids, and to facilitate distribution of steam or other gases to the solids above the plate 11 from a supply pipe 14. rlhe pipe 11i is valved l at 15 for controlling intake or discharge through the pipe. `The pipe la vis also branched at 16 and 17, the branch 16 being adapted to receive a supply of steam, `while the branch liis designed to direct fluid discharged from the lower end of chamber 9 to Va point or points for further treatment, such,

for example, as return to the header 4l. A valve 18 controls the vbiaiichl, and a valve 19 controls the branch 1T. The chamber 9 is provided with a series of vertically spaced discharge pipes, such as seen at-20, 21, 22 and rolled by a valve 24, and all communicating with a discharge pipe 25 extending to a. circulating pump 26 which fin turn communicates with a pipe 2T for returning liquids drawn from the chamber 9 to the header l. n i

Rising lfrom the top or upper end portion of chamber 9 is the vapor line 28 which communicates with the lower portion of the defiegmator 29.l At an appropriate point in theV length of the vapor line 28, a super-.heater 6 is provided, as shown in detail in Figures 5, 6 and 7 of the drawingsand hereinafter described. The deflegmator 29 may be of the ordinary well known conventional type, and is yprovided with a return leg 30 extending to and communicating with the pipe 25 for returning the `heavier liquids to the heater 2.

The deflegmator 29 has its upper portion communicating through a pipe 3l with means for reducing the'higher volatiles to a liquid state. One of such means may be theconventional condenser 32arranged in the chilling tank 33, which latter is adapted to be cooled by refrigeratingcoils 34. rlhe condenser 32 discharges through a pipe 35 into atank 36. Pipe 35 is valved at`45 for controlling the discharge into the tank 36. rlank 36 is preferably provided with a drain pipe 37, valved at 38, for drawing olil water, or otherheavier liquid products. A pipe 39 leads from tank 36 and is valved at 40 for drawing off the blended hydrocarbon fuel in the form of the commercial products. The draw-off pipe 37 communicates preferably vat the lowermost point oftank 36, while pipe 39 communicates with a higher point.

lahile thecondenser is preferred for treating some of the heavier Aof the more volative distillates, it is not essential to use said condenser, and especially when the more highlyv volatile distillates are being recovered. Such lighter vapors are preferably liquefied by a pressure difference or vacuumcliilling process hereinafter this end, the pipe 3l is valued at 4l, and the pipe 35 is valved at 42. A by-pass 43, valved at 44, communicates with the pipe 3l above the valve 41 and below the valve 42, so that by closing the valves 42 and 41 and opening the valve 44, the condenser 32 may be cut out of the system. Vhen the parts have assumed this position, the gases discharging from deflegmator 29 reach the pipe 35 in their gaseous' state, and to reduce vthem to liquid form a branch pipe 46 communicates with the pipe 35, and is valved at 47. Pipe 46 communicates with a tank 48, preferably having the pressure gauge 49. A' series of discharge pipes, `preferably of relatively small bore, communicate with the lower portion of the tank 48, as indicated at 50, 50, each having a valve 5l and each discharging into a vacuum tank '52. The vacuum tank 52 communicates through a pipe 53,

valved at 54, with an injector pump 8O which in turn communicates through pipe 81 with tank 48. Pipe 8l is valved at 82, and pump 8O serves-to force fixed gases from tank 52 `back into tank 48.

A pipe 55 leads from tank 36 back to the tank l for equalization of pressure when the entire system is operating under pressure, the pipey 55 being valved at 56 relatively near. the tank 36, and also valved4 at 57 preferably `relatively near the Ysource of .supply l. A

branch pipe 58 extends from pipe 55, prefdescribed. f To erably between the valve 56 and 57, to the' deiiegmator 29, and is valved at 59. -A

' erably between the tank 36 and valve 56, and

the branch 60 is valved at 6l.l The branch 60 communicatesY with a vacuum pump, not illustrated. A pipe 62 leads from the lower portion of tank 52 preferably to the lower portion of tank 36.

' Supply tan'l l is preferably arranged to receive waste heat fromthe heater 2, so that the lighter volatiles rise to the upper-portions of tank l. Ardiscliarge pipe or vapor line 63 valve-d at 63 is, therefore, preferably 'providedleading from the upper portion of the tank l to the lower potion of the deflegmator 29. It is to be observed that the vapor lines 28 and 63 preferably taper toward the deflegmator 29, or, in other words, each `has an enlarged receiving end for its source of supply of vapor for facilitating eXit of vapor from such source of supply.y i

'The heater 2may be of any of various types, including the conventional "furnace, for this character of work, as indicated in Figure 4 and hereinafterr described in detail, but by preference said heater is electrical as indicated and consists of a series of individual units 3 as heretofore mentioned. Each unit '3 communicates at each end through a detachable union 64, and a valve 65 with the'respective header 4 oi' 5, so that by the turning off of the two valves 65 and the opening of the unions 64 any particular unit 3 may be removed and a new oneV replaced without stopping or in any way inter` fering with the operation ofthe balance of the heater. Each of said heating units preferably consists of a number of transversely arranged relatively short sections of pipe 66, each section'66 communicating through i a nipple 67'with one end of the adjacent section 66 at one side and through a nipple 68 with the relatively opposite end of the ad- ]acent section 66 at the other side.' vThe terminal sections 66 have their nipples 67 or 68 (as the case may be) communicating with the respective union 64, and thencethrough the valve 65 to the header. As best seen in Figure 3, each section 66 contains an electrical resistor 69 engaged at each end by an insulator 70 rigidly Vclamped in placeby a sleeve nut 71 threaded'into the T-fittin'g.4

forming the pipe connection between the given section 66 and its respective nipple 67 `or 68. The resistor 69'has a reduced shank-` which may be of metalV or otherwise, indicated at 72,-pro]ecting beyond the insulation 70 and beyond the sleeve nut 7l. and inl electrical communication with a bus line 73.` As each end of each of the resistors169 and its connected parts is a duplicate of the other `only one has been shownin detail, and it will,` y vbe understood that the insulator 7 Oatone end 'i of each resistor 69 clamped by the nut 71.

against the annular shoulder of the resistor 69 at the place of outstanding of the shank 72 is stressed by the said nut 7l toward the other insulator 70 in the direction of the length of the resistor 69, and the resistor 69 is accordingly effectively clamped rigidly in place within its respective pipe section 66. Each resistor 69 is of dimensions sufficient for leaving only a relatively thin wall of crude petroleum, or other fluid fuel to be heated, about it within the respective section 66. liso each resistor 69 is formed of carborundum with a bonding agent utilized in production assuring a stable, solid rod of resistino' material having a natural lack of affinity for carbon and affording practically no occasion for short circuiting incrustations. Attempts have been heretofore made or proposed for heating oil by the use of wire resistances of the well known coil type, but in every instance of such attempts, so far as known by me, wholly unsatisfactory and unsuccessful results lave followed, because of collections carbonaceous material on the coils of wire short circuiting areas thereof, lowering the res'itance, and causing overload to the point of burning out the resist- Similar and other objectionable reave followed attempted use of ordiaphite carbon sticks, but these'results occur in the use of the carborundum Y,lf'hile l have referred to f being preferably made -"unduin end an appropriate bonding ey may be made of any other mal apable of affording the ance both to the flow of curthe eroding influences of hot -rieal furnaces may be employed, such, for example, as the commercially known glow bars, and I find the use of carborundum in vthe formation of resistors 69 very valuable from their capacity for prolor ed successful use. All resistance heretofore proposed to be used for heating liquid in whichL they are submerged either rupture from rising resistance and overload,

is the case with coiled wire, or else the reistance is lowered and the heat emanaton disastrously reduced, as is true of graphite carbon; whereas with the reistor bar of carborundum the oil or Ather liquid finding its way into the interstices of the resistor 69 lowers the resistance in about the ratio in which the resistance would otlier-Y e rise, so that the actual resistance remains approximately constant, and continued use of the bar resistor 69 does not lead to an ultimate defective condition. There is no overloading and resultingJ rupture, yand no dropping of heat generation.

lt will he obvious that the required difference of potential being maintained between the two bus lines 73 of each of the units 3,

the several resistors 69 will have their temperature raised by the current to the glowing point, and the oil approaching from header l and flowing toward header 5 will increase in temperature as it advances along the successive pipe sections 66 until, by the time the oil has reached the header 5, it has attained cracking temperature. The pipe fittings utilized in making up each of the units 3 are preferably of the high pressure type.

The vapor line 28, as above stated, is provided with an electrical super-heater 76, such as is illustrated in detail in Figures 5, 6 and 7 in which heater 76 is seen as a flattened drum or housing tapering at its ends to conform to and unite with the adjacent portions of the vapor line 28 and widened and made relatively thin throughout intermediate por-` tions for accommodating a series of electrical heating units, each consisting of a resistor 77 identi-cal in construction and mounting with resistor 69. Each resistor 77 is clamped in place by insulating sleeves correspond-- ing to the insulating sleeves and engaged by sleeve nuts 78, 76, corresponding in structure, function and arrangement to the sleeve nuts 7l. Current being supplied to the several resistors 77, the heat produced thereby is delivered to the passing vapors and raises them say to approximately i800O F., that is sufficiently high to cause the hydrogen in the vapors to combine with the available carbon therein. Carbon freed from the treated coal will be available. lt should be understood that no contention is made by me of any special virtue from electrolysis incident to the exposure of the vapor in the case of the vapor heater 76 to Contact with the non-insulated surface of ciurent conductors, or of any electro-lytic action incident to contact in the units 3 of hydrocarbon oil direct with the non-insulated surface of current conductors. 'It is my conviction that little, if any, effect is produced by any electrification of the vapor or oil. l reserve, however, to myself the benefit of any possible advantages that may arise incident to electrolytic action that may occur incident to my invention should later experimentation demonstrate that valuable results do flow from such ac-` tion. y

In carrying out that part of the present invention comprising the art or process, current is turned on to the bus lines 73, and fuel, such as crude petroleum, is delivered from tank 1 to header 1l, and through the units 3 to header 5, and thence into rthe chamber 9. Before this operation is started, however, the chamber 9 is charged with the fuel to be cracked, such, for illustration, as a goed grade of bituminous coal mixed with calcium oxide. The proportions of the mixture will be varied according to other factors, such as the moisture content of the'coal and the ability of the coal to give off free carbon ies When steam is supplied While the coal is hot. bottom 1l. After the clean-out, a new charge By Way of ez-ample, coal containing ten per per centum moisture Will reduce approximately four hundred pounds of calcium 0X- ide per ton of coal, depending upon the kind and quantity of oxide used. The oxygen Will combine with the hydrogen of the moisture and leave the calcium residuum. If steam is to be supplied, a greater amount of the oxide must beV proportionally utilized, and the steam must be injected in small quantities ata time so that the temperature Will not be too greatly reduced.

rlChe oil or liquid fuel jetting from the spout lO cataracts upon the solids Within the chamber 9 and at iirst percolates down through the solids. rlFhe valve 'i5 is preferably closed, and the valves 24 of pipes 2l, 22 and 23 are also preferably closed. The liquid percolatingthrough the solids fills the lower portion of the chamber 9 to the e`evation of the pipe 2l, and then flows out through the pipe 2l, pipe 25, and pump 26 back to the header 4e. The plant is kept on stream, that is this circulation continues'until the liquid passing the heater 2 reaches a cracking temperature. Thereupon vapors begin to rise through the vapor line 28 and the circulation continues With ever increasing temperature of the solids in chamber 9 until the solids begin to crack also and their vaporous vapors rise to mingle with that of the intloiving and cracking oil, and the mingled vapors pass out through the vapor line 28 the deilegmater 29. This operation continues until the Solids in the chamber 9 have either melted or coked. 1When melting, portions ot the liquefied solids, mingling With the descending oil, will remain fluid and pass on with the oil. Burthe operation to this point. the moisture Within the coal Will have been driven off and the hydrogen therefrom combining with free carbon from the solids either in the cracking chamber or in the super-heater, passing oil as a hydrocarbon vapor, and the oxygen nyvhile is taken care oi by the oxide. The solids may then be further and largely reduced by the injecting et steam While the solids are maintaA ed hot incident to the continuation ot' the oil circulation and delivery to chamber at a cracking temperature. rlhe plant ivill be continued on stream until not only pipe 2O has been clogged,I but alloic 2l, 22 and 23 successively Clogger. `When the last-named pipe has ceased to discharge into pipe 25, the plant must be shut down and chamber 9 cleaned out. Under certain conditions, it may be desirable to carry out the cleaning out process at an earlier period. The rei uum from the calcium oxide employed blending with the asphaltum products from the coal and eil will produce an improved pavinp asphaltum. The chamber 9 may be cleaned out readily by the removal of the bottom 13, the frame-Work 12, and false densates directly to the tank is supplied and the operation is repeated. To avoid delay incident to cleaning chamber 9, two such chambers may be provided, and pipe 5 and vapor line 28 branched thereto, so that one of the chambers may be in use and the plant kept on stream While the other is being cleaned.

l/Vhile the cracking process is progressing as stated, the heat from heater 2, raising the temperature of the contents of the supply tank l (said tank being preferably especially located to receive the Waste heat) will cause the lighter volatiles in tank l to rise to the upper part thereof and to discharge through vapor line 53 to the deflegmator 29.

The substances moving through vapor lines 28 and 63 to the deliegmator 29 which are too heavy to go over the top of the detlegmator are discharged down the pipe 30 and back int-o the circulatingpipe 25. T he lighter vapors pass over the deflegmator and down through the condenser 32 and into the tank 36. lVhil-e this is occurring, the valves l1 and 42 are open and the valves le and 47 are closed. During this operation the pressure is maintained equalized throughout the system by the opening of the valves 56 and 57 and the closing of the valves 5l, 54 and 61.

nvever, it may become desirable to treat vapors without theuse of the condenser 32, an d this is especially true with lthe more volatile vapors. The pressure difference or vacuum chilling` operation is then utilized. For this purpose, the valves 38, 40, 41, 42,45, 54 and 56, are closed, and valves lll and 47, 51, 59

and G1 are opened. Of course, if pump 80 is f vapor Within the tank 48. Said vapor is,

therefore, discharged in a series of relatively line streams through pipes 50 into the vacuum area ot the tank 52, and the resulting er; ansien of the as it enters the tank 52 causes a lowering of the temperature which produces condensation of such gas. The liquid thus produced then flows down the pipe 62 into tank 36, andV is usually accompanied by certain unreduced lifted gases which pass up through the body of liquid in container 36 and are 'further chilled thereby, and minglinff therewith are to a further degree reduced til liquid. lVhen this operation occurs imme.- diately following the delivery of liquid con- 1 n L 36 from the condenser e2, the liquid condensates of the lighter gases will blend in tank 36 with the heavier condensates, and the resulting distillate Will be highly saturated, and a relatively small amount of uncondensed gases Will remain. Of course, the uncondensed @as drawn oli through pipe`v60 may be compziessed and re- Aturned to the system for further treatment or otherwise utilized.

lt will, of course, be readily understood that while a vacuum or partial vacuum is herein referi'ed to, the chilling effect of expansion of in tank 52 is readily obtained by the difference in pressure between tanks and 52 and that difference may easily be maintained with-out even a partial vacuum. The-terni vacuum7 is, therefore, herein used to signify any difference in pressure anording the results stated. Also, it is to be borne in mind that the valves 51 are to be carefully manipulated by the operator incident to observance of the difference in pressure between tanks 48 and 52. Gauge 49 on tank 48 and a gauge S3 on tank U6 should be carefully watched as showing` such difference in pressure, and the valves 5l opened or closed in greater or less number according to the capacity of tank 52 and conditions of relative pressure therein t-o effect the desired chilling expansion of injected vapors. The ends of pipes 50 opening into tank 52 may be formed and arranged in any acceptable manner susceptible of affording the results stated. It is, however, preferable to utilize an injector jet at the discharge end of each pipe 50 Such a jet as is commonly called a Venturi nozzle, as seen at 84 in the drawings, is found very effective, but other types of jets may be used and give effective results.

lt will be noted that the pressure in the system is created and maintained by the expansive force of the vapors without the aid of a pressure or injection pump, and that the pressure being equalized oil is lfed by gravity directly from the supply tank 1 into the system.

Since it is desirable that the lighter distillates and uncondensed gases passing down pipe 62 shall have maximum opportunity for blending with the column. of'liquid in tank 36, l prefer to provide a distributing pipe 85 with which the lower end of pipe 62 communicates, the pipe 65 extending along the tank 36 near the lowermost portion thereof and being formed with small apertures distributed along the length of the pipe 85 for the escape of the products descending through pipe 62. Vfhile the liquid drawn from pipe 39 may be considered the finished product, it is so onlyT relative to the plant and process herein set forth. Of course, the product discharged through pipe 39 may be further refined or otherwise treated as found desirable.

It should be understood, of course, that the entire plant will be protectedbysuch pressure gauges and temperature indicating ap- ;aratus as are commonly employed, and that they will be distributed throughout the plant wherever required though not illustrated in the drawings. Also, all parts will be heatinsulated where required and particularly the deflegmator 29 will be provided with means for controlling temperatures for maintaining eifective operating conditions. That is to say, the upper portion of the deflegmator will be kept at that temperature which will effect discharge of gases to the condenser according to the character of the distillate desired to be recovered. Too high temperature may be reduced by the employment of cooling medium circulating coils located about or within the deilegmator, not illustrated; and cooling below the required temperature within the deiiegmator will be prevented by exterior insulation. The deflegmator itself is of the form commonly in use.

The final products obtained, in their natural sequence, are a high quality, anti-knock hydrocarbon internal combustion motor fuel, a distillate of fuel oil of exceptionally good quality for fuel oil burners, and a superior quality of paving asphaltum or a good quality of commercial coke. i

`What is claimed is f l. An electrical heating unit for a circulating system of apparatus for recovery of hydrocarbon from carbonaceous material comprising resistors and housings for directing the flow of carbonaceous material in contact with the resistors in a continuous, uninterrupted stream, each resistor and housing being proportioned relative to each other for causing the stream to assume the form of a relatively thin iilm exposed to the heat of the resistor, each resistor being substantially impervious to hydrocarbon liquid at high temperature.

2. In apparatus for recovery of hydrocarbon fuel from carbonaceous material, an electrical heating unit comprising a tube, an electrical resistance bar therein and extending longitudinally thereof and having a terminal outstanding beyond the end of the tube, the bar being directly exposed to contact with the contents of the tube,and means for detachably closing said end of said tube, the resistance bar being substantially inipervious to hydrocarbon fluid at high temperature.

8. In apparatus for recovery of hydrocarbon fuel from carbonaceous material, an electrical heating unit comprising a tube, an electrical resistance therein and extending longitudinally thereof and having a terminal outstanding beyond the end of the tube, the resistance being directly exposed to contact with the contents of the tube, and means for detachably closing said end of said tube, said resistance consisting of bar material, the resistance bar being substantially l longitudinally thereof and having a` tertact with the contents of the tube, and means for detachably closing said end of said tube, said resistance consisting of bar material,

and said bar material being dimensioned relative to the tube for spreading the liquid passing` through the tube and maintaining it in a relatively thin sheet about the walls of the tube, the resistance bar being substantially impervious to hydrocarbon Huid at high temperature.

6. In apparatus for recovery of hydrocarbon fuel from carbonaceous material, an electrical heating unit comprising a tube through which the carbonaceous material is adapted to be moved, and an electrical resistance bar within the .tube located to directly contact with the carbonaceous material passing therethrough, the resistance bar being substantially impervious to hydrocarbon fluid at high temperature.

7. In apparatus for recovery of hydrocarbon fuel from carbonaceous material, an electrical heating unit comprising a tube through which the carbonaceous material is adapted to be moved, and an electrical resistance bar within the tube located to directly contact with the carbonaceous material passing therethrough and proportioned to occupy sulficient of the space within the tube to maintain the carbonaceous material within the tube in a relatively thin sheet, the resistance bar being substantially impervious to hydrocarbon fluid at high temperature.V

8. In apparatus for recovery of hydrocarbon fuel from carbonaceous material, electrical heating apparatus comprising a series of tubes arranged to form a column with the tubes substantially at right angles to the column, means of communication between the tubes, the said tubesbeing adapted to have carbonaceous material moved therethrough, and an electrical bar resistance arranged within each of the tubes in position for dif rect Contact with carbonaceous material therein, the resistance bar being substantially impervious to hydrocarbon fluid at high temperature.

9. In apparatus for recovery of hydrocarbon fuel from carbonaceous material, electrical heating apparatus, comprising a series of tubes arranged to form a column with the tubes substantially at right angles to the column, means of communication between the tubes, the said tubes being adapted to have carbonaceous material moved therethrough, and an electrical bar resist-ance varranged within each of the tubes in position for direct contact with carbonaceous material therein, each of said bar resistances being detachably mounted for endwise removal from its respective tube, each of the resistance bars being substantially impervious to hydrocarbon fluid at high temperature.

10. In apparatus for recovery of hydrocarbon fuel from carbonaceous material, electrical heating apparatus comprising a series of tubes arranged to form a column with the tubes substantially at right angles to the column, means of communication between the tubes, the said tubes being adapted to have carbonaceous material moved therethrough, and an electrical bar resistance arranged within each of the tubes in position for direct Contact with carbonaceous material therein, the means of communication between the several tubesbeing located at alternate opposite ends thereof for` connecting the tubes in a series, each of the resistance bars being substantially impervious to hydrocarbon fluid at high temperature.

In testimony whereof I afliX my signature.

RUSSELL CARTER. 

